Composite yarn, fabric, and fiber product

ABSTRACT

A problem of the present invention is to provide a composite yarn, a fabric, and a fiber product, which are excellent in cotton-like appearance, texture, and snagging resistance, and preferably excellent in see-through-preventing properties and water absorbing and quick drying properties. The solution is to obtain a composite yarn using a thick and thin yarn and a crimped yarn and to obtain a fabric, if desired.

TECHNICAL FIELD

The present invention relates to a composite yarn, a fabric, and a fiberproduct, which are excellent in cotton-like appearance, texture, andsnagging resistance, and preferably excellent in see-through-preventingproperties and water absorbing and quick drying properties.

BACKGROUND ART

Polyester filament fibers typified by polyethylene terephthalate (PET)are widely used for clothing, industrial materials, and the like.However, due to characteristics of a manufacturing method thereof, theyinvolve such defects that as compared with natural fibers and spunyarns, the thickness unevenness is small, and the texture and theappearance change are poor.

In order to eliminate such defects, there is proposed a method forimparting thickness unevenness to a polyester fiber by controlling thelength of an unstretched portion of a highly oriented polyesterunstretched yarn, thereby imparting an arbitrary splashed pattern-likeappearance to the fabric (see, for example, Patent Literature 1 andPatent Literature 2).

However, it could not be said that such a fabric is satisfactory interms of cotton-like appearance, snagging resistance, and so on.

CITATION LIST Patent Literature

Patent Literature 1: JP 60-199941 A

Patent Literature 2: JP 7-229030 A

SUMMARY OF INVENTION Technical Problem

In view of the aforementioned background, the present invention has beenmade, and an object thereof is to provide a composite yarn, a fabric,and a fiber product, which are excellent in cotton-like appearance,texture, and snagging resistance, and preferably excellent insee-through-preventing properties and water absorbing and quick dryingproperties.

Solution to Problem

In order to achieve the aforementioned problem, the present inventorsmade extensive and intensive investigations, and as a result, they haveled to accomplishment of the present invention.

Thus, in accordance with the present invention, a “composite yarncontaining a thick and thin yarn and a crimped yarn” is provided.

On that occasion, it is preferred that the aforementioned thick and thinyarn is a non-crimped yarn.

In addition, it is preferred that the composite yarn contains theaforementioned thick and thin yarn in a ratio within a range of 30 to852 by weight relative to the weight of the composite yarn. In addition,it is preferred that the composite yarn is interlaced such that aninterlace number is 120 or less per meter. In addition, in the compositeyarn, it is preferred that the thick and thin yarn and the crimped yarnare interlaced with each other; or a non-aligned part in which the thickand thin yarn is located in a core, and the crimped yarn is located in asheath is intermingled with an aligned part in which the thick and thinyarn and the crimped yarn are in an aligned state. In addition, in thecomposite yarn, it is preferred that the non-aligned part is 40 to 95′relative to the length of the composite yarn. In addition, in thecomposite yarn, it is preferred that the aligned part is 5 to 40%relative to the length of the composite yarn. In addition, it ispreferred that a single fiber fineness of the thick and thin yarn is 1.5dtex or more. In addition, it is preferred that a single fiber finenessof the crimped yarn is 1.0 dtex or less. In addition, it is preferredthat the thick and thin yarn and/or the crimped yarn is made of apolyester fiber or a nylon fiber. In addition, it is preferred that thethick and thin yarn and/or the crimped yarn is made of a chemical ormaterial recycled polymer. In addition, it is preferred that the thickand thin yarn and/or the crimped yarn is made of a cationic dyeablepolyester. In addition, it is preferred that in the thick and thin yarnand/or the crimped yarn, the content of a matting agent is 0.1% by massor more.

In accordance with the present invention, a fabric containing theaforementioned composite yarn is provided. On that occasion, it ispreferred that the fabric is a knitted fabric having a density of 35 to100 courses/2.54 cm and 30 to 100 wales/2.54 cm. In addition, it ispreferred that a snagging resistance as tested for 15 hours by using ahacksaw according to JIS L1058-1995 D-3 Method is grade 3 or more.

In addition, in accordance with the present invention, a fiber productmade of the aforementioned composite yarn or fabric, which is any oneselected from the group consisting of sportswear, outerwear, innerwear,men's clothing, women's clothing, nursing clothing, work clothing, carseat skin material, and bedding, is provided.

Advantageous Effects of Invention

In accordance with the present invention, a composite yarn, a fabric,and a fiber product, which are excellent in cotton-like appearance,texture, and snagging resistance, and preferably excellent insee-through-preventing properties and water absorbing and quick dryingproperties are obtained.

DESCRIPTION OF EMBODIMENTS

Embodiments of the present invention are hereunder described in detail.First, the composite yarn of the present invention is a composite yarncontaining a thick and thin yarn and a crimped yarn.

Here, it is preferred that the composite yarn contains the thick andthin yarn in a ratio within a range of 30 to 85% by weight (morepreferably 51 to 80% by weight) relative to the weight of the compositeyarn. In addition, it is preferred that a weight ratio of the crimpedyarn (relative to the weight of the composite yarn) is within a range of15 to 70% by weight (more preferably 30 to 48% by weight). In the casewhere the weight ratio of the thick and thin yarn (relative to theweight of the composite yarn) is smaller than the foregoing range, thereis a concern that the excellent cotton-like appearance is not obtained.In addition, in the case where the weight ratio of the thick and thinyarn is larger than the foregoing range, there is a concern that thesnagging resistance of the fabric is lowered.

Here, though the thick and thin yarn may be a crimped yarn, it ispreferably a non-crimped yarn. When the thick and thin yarn is anon-crimped yarn, in view of the fact that a difference in crimp betweenthe thick and thin yarn and the crimped yarn is large, the thicknessunevenness in the composite yarn becomes large, and excellentcotton-like appearance and texture are developed. In addition, in thecase where the non-crimped yarn is disposed in a core of the compositeyarn, and the crimped yarn is disposed in a sheath of the compositeyarn, the water absorbing and quick drying properties are improved dueto capillary phenomenon.

Examples of the thick and thin yarn include a thick and thin yarn havingthickness unevenness similar to a spun yarn and also having randomthickness unevenness between single fibers as described in JP2000-234232 A; and a thick and thin yarn obtained by non-homogeneousstretching using a frictional resistor as described in JP 7-324237 A.

On the other hand, though the crimped yarn may be a crimped yarn inwhich latent crimp of side-by-side type conjugate fiber is visualized,it is preferably a false-twist crimped textured yarn.

The type of the polymer forming the thick and thin yarn and/or thecrimped yarn is preferably a polyester or an aliphatic polyamide (e.g.,nylon 6 and nylon 66). Above all, there are more preferably exemplifiedpolyethylene terephthalate, polytrimethylene terephthalate, polybutyleneterephthalate, polylactic acid, and a polyester resulting fromcopolymerization with a third component. Such a polyester may also be amaterial recycled or chemical recycled polyester. Furthermore, thepolyester may also be a polyester obtained by using a catalystcontaining specified phosphorus compound and titanium compound asdescribed in JP 2004-270097 A and JP 2004-211268 A. If desired, thepolyester polymer may contain therein one or more of a micropore formingagent, a cationic dye dyeable agent, a coloring inhibitor, a thermalstabilizer, a fluorescent brightening agent, a matting agent, a coloringagent, a moisture absorbent, and inorganic fine particles within a rangewhere the object of the present invention is not hindered. Inparticular, when the matting agent is contained in a ratio of 0.1, byweight or more (more preferably 0.3 to 2.0V by weight) relative to theweight of the polymer, the see-through-preventing properties areimproved, and hence, such is preferred. Specifically, a semi dullpolyester and a full dull polyester are preferred. In addition, when thecationic dye dyeable agent (e.g., a polyester-forming sulfonic acidmetal salt compound is contained), antibacterial and deodorizationproperties are added by performing an acid treatment as described in WO2011/048888 A, and hence, such is preferred.

In the thick and thin yarn, a total fineness thereof is preferably 22 to400 dtex (more preferably 30 to 60 dtex). In addition, a single fiberfineness of the thick and thin yarn is preferably 1.5 dtex or more (morepreferably 1.5 to 3.0 dtex). In addition, a filament number of the thickand thin yarn is preferably 12 to 200 (more preferably 20 to 60).

In the crimped yarn, from the standpoint of obtaining the excellentcotton-like appearance and snagging resistance, a total fineness thereofis preferably smaller than that of the thick and thin yarn. Inparticular, the total fineness of the crimped yarn is preferably 18 to333 dtex (more preferably 20 to 50 dtex). In addition, a single fiberfineness of the crimped yarn is preferably 1.0 dtex or less (morepreferably 0.1 to 1.0 dtex). In addition, a filament number of thecrimped yarn is preferably 12 to 200 (more preferably 20 to 60). Inaddition, a crimp degree of the crimped yarn is preferably within arange of 2 to 40% (more preferably 5 to 35%).

Although the composite yarn of the present invention is preferablyconstituted of only the thick and thin yarn and the crimped yarn, it maycontain other fibers. In addition, although the composite method is notparticularly limited, it is preferred that the thick and thin yarn andthe crimped yarn are aligned and interlaced (air-mixed).

On that occasion, an interlace number is preferably within a range of200 or less per meter (more preferably 120 or less per meter, andespecially preferably 20 to 120 per meter).

In the composite yarn, it is preferred that the thick and thin yarn andthe crimped yarn are interlaced with each other; or a non-aligned partin which the thick and thin yarn is located in a core, and the crimpedyarn is located in a sheath is intermingled with an aligned part inwhich the thick and thin yarn and the crimped yarn are in an alignedstate. Such a composite yarn is, for example, obtained by obtaining athick and thin yarn having thickness unevenness similar to a spun yarnand also having random thickness unevenness between single fibersaccording to the method as described in Example 1 of JP 2000-234232 A,followed by aligning the thick and thin yarn and the crimped yarn andinterlacing.

Here, in the composite yarn, it is preferred that the non-aligned partis 40 to 95% relative to the length of the composite yarn. In addition,in the composite yarn, it is preferred that the aligned part is 5 to 40,relative to the length of the composite yarn. However, it is to be notedthat each of those ratios is one obtained by extracting 10 compositeyarns (20 cm) from the fabric, calculating each of the ratios relativeto the composite yarn (20 cm), and then determining an average of the 10yarns.

The fabric of the present invention contains the aforementionedcomposite yarn. In such a fabric, the structure of the fabric is notlimited, and may be one obtained by knitting and weaving by a usualmethod.

Examples of the weave structure include three foundation weaves, such asplain weave, twill weave, and satin woven fabric; modified weaves;modified weaves, such as modified twill weave; one-side backed weaves,such as warp-backed weave and weft-backed weave; and warp velvet. Inaddition, examples of the knitted fabric include jersey stitch and halftextures, half-base textures, or satin textures obtained using 2 reedsor 3 reeds. In particular, a knitted fabric having a density of 35 to100 courses/2.54 cm and 30 to 100 wales/2.54 cm is preferred from thestandpoint of water absorbing and quick drying properties.

A basis weight of the fabric is preferably within a range of 70 to 130g/m².

To such a fabric, dyeing, water absorption, embossing, coloring andprinting, and water repellent finishing, and various processingsimparting functions of a UV shielding agent, an antibacterial agent, adeodorant, an insect repellent, a luminous agent, a retroreflector, anda minus ion generating agent, may be additionally applied.

The thus obtained fabric has excellent cotton-like appearance, excellenttexture, excellent texture, snagging resistance, see-through-preventingproperties, and water absorbing and quick drying properties. On thatoccasion, it is preferred that the snagging resistance as tested for 15hours by using a hacksaw according to JIS L1058-1995 D-3 Method is grade3 or more.

Next, the fiber product of the present invention is a fiber product madeof the aforementioned fabric, which is any one selected from the groupconsisting of sportswear, outerwear, innerwear, men's clothing, women'sclothing, nursing clothing, work clothing, car seat skin material, andbedding.

Since such a fiber product uses the aforementioned fabric, it isexcellent in cotton-like appearance, snagging resistance,see-through-preventing properties, and water absorbing and quick dryingproperties.

EXAMPLES

Next, the present invention is described in detail by reference toExamples, but it should be construed that the present invention is by nomeans limited by these Examples.

(1) Basis Weight

The basis weight (g/m²) of a woven fabric was measured by JISL1096-2010.

(2) Snagging Resistance

The test was performed for 15 hours by using a hacksaw according to JISL1058-1995 D-3 Method.

(3) Crimp Degree

The crimp degree was measured by the following method.

That is, a test filament thread is wound around a sizing reel having aperipheral length of 1.125 m to prepare a skein having a dry fineness of3333 dtex.

The skein is hung on a hanger nail of a scale plate. An initial load of6 g is applied to the lower part thereof, and a further load of 600 g isapplied; and the skein length at that time is measured as L0. The loadis then immediately removed from the skein, and the skein is removedfrom the hanger nail of the scale plate and immersed in boiling waterfor 30 minutes, thereby allowing crimps to be developed. The skeintreated with boiling water is taken out from boiling water, and moisturecontained in the skein is removed by absorption on a filter paper. Theskein is then air-dried for 24 hours at room temperature. The air-driedskein is hung on a hanger nail of a scale plate. A load of 600 g isapplied to the lower part thereof, and the skein length is measuredafter 1 minute as L1a. The load is then removed from the skein, and theskein length is measured after 1 minute as L2a. The crimp degree (CP) ofthe test filament thread is calculated according to the followingequation.

CP(%)=(L1a−L2a)/L0)×100

(4) Degree of Interlace

An interlaced yarn is taken by a length of 1 m under a load of 8.82mN×(nominal tex) (0.1 g/de), and after removing the load, the yarn isallowed to contract at room temperature for 24 hours, followed byreading the number of nodes, a value of which is indicated in terms ofnodes/m.

(5) Ratios of Non-Aligned Part and Aligned Part in Composite Yarn

Ten composite yarns (20 cm) were extracted from the fabric, each of theratios relative to the composite yarn (20 cm) was calculated, and anaverage of the 10 yarns was determined.

(6) Spun-Like Appearance

The spun-like appearance was evaluated according to criteria of threestages of “∘” (excellent), “Δ” (moderate), and “x” (inferior) by visualjudgment by the tester.

Examples 1 to 5 and Comparative Examples 1 to 2

Non-crimped thick and thin yarns as shown in Table 1 each havingthickness unevenness similar to a spun yarn and also having randomthickness unevenness between single fibers were obtained according tothe method described in Example 1 of JP 2000-234232 A. In addition, inExamples 1 to 5, the false-twist crimped textured yarn shown in Table 1was obtained by a conventional method. In Table 1, “FD” indicates achemical recycled full dull polyester; “SD” indicates a chemicalrecycled semi dull polyester; and “CD” indicates a chemical recycledcationic dyeable polyester. In addition, for example, the term “44T36”means one having a total fineness of 44 dtex and a filament number of36.

Subsequently, in Examples 1 to 5, the thick and thin yarn and thefalse-twist crimped textured yarn were aligned and interlaced, therebyobtaining a composite yarn in which the thick and thin yarn and thecrimped yarn were interlaced with each other, or in which a non-alignedpart where the thick and thin yarn was located in a core and the crimpedyarn was located in a sheath was intermingled with an aligned part wherethe thick and thin yarn and the crimped yarn were in an aligned state.Subsequently, knitted fabrics were obtained using a circular knittingmachine as shown in Table 1.

In Example 1, the non-aligned part was 74%, and the aligned part was26%. The evaluation results of Examples 1 to 5 and Comparative Examples1 to 2 are shown in Table 1.

TABLE 1 Comparative Comparative Example 1 Example 2 Example 3 Example 1Example 2 Example 4 Example 5 Yarn Thick and thin yarn FD44T36 FD44T36FD44T36 FD110T36 FD66T72 FD33T36 FD33T36 False-twist crimped Yarn typeFD33T36 SD33T72 CD33T36 — — FD44T36 FD33T36 textured yarn Crimp degree(%) 26 6 15 — — 25 40 IL number (per meter) 100 98 98 — — 110 123 Totalfineness 77T72 77T108 77T72 110T36 66T72 FD77T72 FD77T72 Knitted Type ofknitting machine (gauge) 46 G single 46 G single 28 G single 28 G 28 G46 G 46 G fabric Structure Jersey stitch Jersey stitch Jersey stitchJersey stitch Jersey stitch Jersey stitch Jersey stitch Basis weight(g/m²) 115 113 89 115  105  110 110 Course (per 2.54 cm) 82 75 64 55 9079 79 Wale (per 2.54 cm) 66 72 54 45 73 70 70 Snagging (D-3 Method,grade) 4.5 4.5   4.5  1  1 4.5 4.5 Spun-like appearance ∘ ∘ ∘ x x Δ Δ

INDUSTRIAL APPLICABILITY

In accordance with the present invention, a composite yarn, a fabric,and a fiber product, which are excellent in cotton-like appearance,texture, and snagging resistance, and preferably excellent insee-through-preventing properties and water absorbing and quick dryingproperties are provided, and an industrial value thereof is extremelylarge.

1. A composite yarn comprising a thick and thin yarn and a crimped yarn.2. The composite yarn according to claim 1, wherein the thick and thinyarn is a non-crimped yarn.
 3. The composite yarn according to claim 1,wherein the composite yarn contains the thick and thin yarn in a ratiowithin a range of 30 to 85% by weight relative to the weight of thecomposite yarn.
 4. The composite yarn according to claim 1, wherein thecomposite yarn is interlaced such that an interlace number is 120 orless per meter.
 5. The composite yarn according to claim 1, wherein inthe composite yarn, the thick and thin yarn and the crimped yarn areinterlaced with each other; or a non-aligned part in which the thick andthin yarn is located in a core, and the crimped yarn is located in asheath is intermingled with an aligned part in which the thick and thinyarn and the crimped yarn are in an aligned state.
 6. The composite yarnaccording to claim 5, wherein in the composite yarn, the non-alignedpart is 40 to 95% relative to the length of the composite yarn.
 7. Thecomposite yarn according to claim 5, wherein in the composite yarn, thealigned part is 5 to 40% relative to the length of the composite yarn.8. The composite yarn according to claim 1, wherein a single fiberfineness of the thick and thin yarn is 1.0 dtex or more.
 9. Thecomposite yarn according to claim 1, wherein a single fiber fineness ofthe crimped yarn is 1.5 dtex or less.
 10. The composite yarn accordingto claim 1, wherein the thick and thin yarn and/or the crimped yarn ismade of a polyester fiber or a nylon fiber.
 11. The composite yarnaccording to claim 1, wherein the thick and thin yarn and/or the crimpedyarn is made of a chemical or material recycled polymer.
 12. Thecomposite yarn according to claim 1, wherein the thick and thin yarnand/or the crimped yarn is made of a cationic dyeable polyester.
 13. Thecomposite yarn according to claim 1, wherein in the thick and thin yarnand/or the crimped yarn, the content of a matting agent is 0.1% by massor more.
 14. A fabric comprising the composite yarn according toclaim
 1. 15. The fabric according to claim 14, wherein the fabric is aknitted fabric having a density of 35 to 100 courses/2.54 cm and 30 to100 wales/2.54 cm.
 16. The fabric according to claim 1, wherein asnagging resistance as tested for 15 hours by using a hacksaw accordingto JIS L1058-1995 D-3 Method is grade 3 or more.
 17. A fiber productmade of the composite yarn according to claim 1, which is any oneselected from the group consisting of sportswear, outerwear, innerwear,men's clothing, women's clothing, nursing clothing, work clothing, carseat skin material, and bedding.
 18. The composite yarn according toclaim 2, wherein the composite yarn contains the thick and thin yarn ina ratio within a range of 30 to 85% by weight relative to the weight ofthe composite yarn.